Tgc Series Guillotine Cutter

Transcript

www.conairgroup.com USER GUIDE UGE086-0116 TGC Series Guillotine Cutter 105-555-104 Conair Y=0 M=0 TS Saw K=100 C=0 K=30 Y=0 C=10 M=5 Y=100 K=0 C=50 M=0 Bayfol UV-1 printed 10 mil carrier Second surface backing on white 3M 468 adhesive Black Grey Green Corporate Office: 412.312.6000 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861 Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided. It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment. Date: Manual Number: UGE086-0116 Serial Number(s): Model Number(s): DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose. Copyright 2015 l Conair l All rights reserved Ta b l e o f C o n t e n t s 1-1 Introduction Purpose of the User Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 How the Guide Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Your Responsibilities as a User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ATTENTION: Read This So No One Gets Hurt . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 How to Use the Lockout Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2-1 Description What is the TGC Guillotine Cutter?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Typical Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 How the TGC Series Guillotine Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 TGC Guillotine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 3-1 Installation Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Positioning the TGC Cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Connecting the Main Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Installing the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Installing and Replacing the Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Preparing for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 4-1 Operation TGC Guillotine Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 How to Navigate the Control Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 TGC Guillotine Control Instructions Main Screen . . . . . . . . . . . . . . . . . . . . . . 4-5 TGC Guillotine Control Instructions Menu Screen. . . . . . . . . . . . . . . . . . . . . . 4-6 Control Function Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Control Function Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 The Cutter Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Machine Frame and Support System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Blade Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Upper Clamp Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Control Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Ta b l e o f C o n t e n t s l i 4-1 Operation (continued) Pneumatic Cylinder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Electrical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Chip Collection Shrouds & Blower Connection. . . . . . . . . . . . . . . . . . . . . . . 4-43 5-1 Maintenance (continued) Maintenance Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Checking Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 6 - 1 Tr o u b l e s h o o t i n g Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 A Few Words of Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Product Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 TGC Guillotine Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Checking the Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Checking the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 A Appendix Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 i i l Ta b l e o f C o n t e n t s SECTION 1 Purpose of the User Guide . . . . . . . . . . . . . . . . . 1-2 How the Guide Is Organized . . . . . . . . . . . . . . . . 1-2 Yo u r R e s p o n s i b i l i t i e s a s a U s e r . . . . . . . . . . . . . . 1 - 2 AT T E N T I O N : R e a d T h i s S o N o O n e G e t s H u r t . . . . . . 1 - 3 How to Use the Lockout Device . . . . . . . . . . . . . . 1-4 Introduction l 1-1 1 Introduction Introduction Purpose of the User Guide This User Guide describes the Conair TGC Series Guillotine Cutter and explains step-bystep how to install and operate this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This review won’t take long, and it could save you valuable installation and operating time later. How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation. Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment. Read and take precautions before proceeding. 1 Numbers indicate tasks or steps to be performed by the user. ◆ A diamond indicates the equipment’s response to an action performed by the user. ❒ An open box marks items in a checklist. • A circle marks items in a list. ✒ ✐ Indicates a tip. A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment. Indicates a note. A note is used to provide additional information about the steps you are following throughout the manual. Yo u r R e s p o n s i b i l i t y a s a U s e r You must be familiar with all safety procedures concerning installation, operation, and maintenance of this equipment. Responsible safety procedures include: • Thorough review of this User Guide, paying particular attention to hazard warnings, appendices, and related diagrams. • Thorough review of the equipment itself, with careful attention to voltage sources, intended use and warning labels. • Thorough review of instruction manuals for associated equipment. • Step-by-step adherence to instructions outlined in this User Guide. 1-2 l Introduction AT T E N T I O N : Read This So No One Gets Hurt DA N G E R : S h a r p b l a d e s ! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blade and pneumatics with care at all times. • Always wear cut-resistant gloves when the blade guard is open and when handling blade. • Always lock out the cutter before opening any guards. • Always wait until the Guillotine Cutter has stopped completely before opening the guard. (approximately five minutes) Conair Guillotine Cutters are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury. • The STOP button activates a circuit that stops the Guillotine Cutter. WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r s e r v icing may result in equipment damage or personal i n j u r y. This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. WA R N I N G : Vo l t a g e h a z a r d This equipment is powered by three-phase alternating current, as specified on the machine serial tag and data plate. A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in severe personal injury and erratic machine operation. Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non-standard operating procedures, such as routine maintenance. Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on. 1-3 l Introduction 1 Introduction We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. How to Use the Lockout Device CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or startup. A lockable device has been provided to isolate this product from potentially hazardous electricity. Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device similar to the one shown here. To use the lockout device: 1 Stop or turn off the equipment. 2 Isolate the equipment from the electric power. Turn the rotary disconnect switch to the OFF, or “O” position. 3 Secure the device with an assigned lock or tag. Insert a lock or tag in the holes to prevent movement. 4 The equipment is now locked out. WARNING: Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed, and all safety guards reinstalled. To restore power to the equipment, turn the rotary disconnect back to the ON position: 1 Remove the lock or tag. 2 Turn the rotary disconnect switch to the ON or “I” position. 1-4 l Introduction SECTION 2 Ty p i c a l A p p l i c a t i o n s . . . . . . . . . . . . . . . . . . . . . . 2 - 2 H o w t h e T G C G u i l l o t i n e Wo r k s . . . . . . . . . . . . . . . 2 - 2 T G C G u i l l o t i n e Fe a t u r e s . . . . . . . . . . . . . . . . . . . 2 - 4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . 2-6 Description l 2-1 2 What Is the TGC Guillotine? . . . . . . . . . . . . . . . . 2-2 Discerption Description What is the TGC Guillotine Cutter? Conair’s TGC Series Guillotine Cutter is an on- or off-line guillotine device capable of ondemand cutting of tubes or profiles. Ty p i c a l A p p l i c a t i o n s The TGC Series Cutter can cut extrudable plastics and rubber both on- and off-line. Other extrudable materials-foods, ceramics, magnets, soaps, etc.-may also be cut depending on specific application requirements. Guillotine Cutters are available with different cutting capacities to suit your specific needs. The standard guillotine orientation is right-to-left, cutters can also be made with a left-toright orientation (see Specifications in this section). (The illustrations in this User Guide represent the standard right-to left configuration.) TGC Guillotine Cutters are limited to a specific range of product sizes based on each unit's cutting capacity. Different materials, line speeds, temperatures and material cross-sections can result in different cutting settings. If you are changing any of these parameters, consult your Conair service personnel to be sure your equipment can handle the changes. H o w t h e G u i l l o t i n e C u t t e r Wo r k s The Conair TGC Series Guillotine Cutters are designed for the in-line cutting of profiles, pipe and tubing of a wide variety of sizes. Located as part of the extrusion line downstream of the extruder, the Guillotine Cutter performs five sequential functions in the cut operation as follows: 1 The guillotine table begins to travel with the product in a linear motion then the clamps lock the product to the guillotine cutter head. 2 The guillotine blade travels down and through the product. 3 The guillotine blade returns to its up (home) position. 4 The clamp releases the product. 5 The cutter table returns to its starting (home) position and readies for the next cycle. These functions are preformed automatically with contact closure by means of either depressing the manual cut push button or by activating a flag switch mounted downstream of the unit as standard. There are available options that also initiate the cut cycle including an internal timer, electronic length counter, or any other device that has a N.O. (normally open) contact. 2-2 l Description (Continued) H o w t h e T G C G u i l l o t i n e Wo r k s (continued) Clamps hold the product in place while the blade passes through it during the cutting cycle. 105-555-104 Conair Y=0 M=0 Extruded material enters the guillotine from the upstream side (right-to-left operation). TS Saw K=100 C=0 K=30 Y=0 C=10 M=5 Y=100 K=0 C=50 M=0 Bayfol UV-1 printed 10 mil carrier Second surface backing on white 3M 468 adhesive Black Grey Green Cut pieces are collected on a dump table or carried away on a conveyor. Description l 2-3 T G C G u i l l o t i n e C u t t e r Fe a t u r e s Quick release guards for easy access to the clamps. Self-contained table to reduce machine footprint and enhance safety. 105-555-104 Conair Y=0 M=0 TS Saw K=100 C=0 K=30 Y=0 C=10 M=5 Y=100 K=0 C=50 M=0 Bayfol UV-1 printed 10 mil carrier Second surface backing on white 3M 468 adhesive Black Grey Green Front mounted pneumatic flow controls. Front mounted electrical controls. 2-4 l Description Specifications A C C Side view Front view MODEL Performance characteristics Applications Pipe diameter capacity in. {mm} Profile capacity in. {mm} H x W* Blade width in. {mm} Blade type Cuts per minute Table type Cut/clamp head type* Line rate Machine control Table type Dimensions in. {mm} A - Overall height B - Overall width C - Overall depth D - Height to centerline E -Maximum table travel Electrical requirements TGC Pipe, Tube or Profile 1-5 {25-127} contact Conair varies by application hardened steel (large) or tempered spring steel (small) up to 15 cuts/min depending on material, diam. and wall pneumatic pneumatic up to 40 ft/min {12 meters/min} touch screen HMI pneumatic 68 {1727} 92 {2337} 31 {787} 43 inches {1092 mm} 24 inches {610 mm} 460V/3 phase/60 Hz (others optional) Pneumatic requirements 90 psi {6.2 bar} SPECIFICATION NOTES: *Profile capacity H x W dimensions are provided for guidance only. The actual capacity can vary depending on the profile you are attempting to produce. This table defines standard configurations only. Specifications can change without notice. Contact a Conair representative for the most current information. Description l 2-5 2 E Description D Optional Equipment Left-to-right machine operation This option changes the machine direction from the standard right to left extrusion flow. Different guillotine blades For various material types. Electronic Cut-to-Length measuring system using a digital automatic reset counter with encoder for mounting to customer’s puller. Servo control for optimal cut length and repeatable length accuracy Servo drive package for guillotine table travel system uses an AC servomotor with precision planetary gear drive assembly. A microprocessor supplies signals to the servomotor for accurate control of the guillotine table travel. Operator controls include a touch screen human-machine interface (HMI) for length input settings and table motion synchronization. The command signal is supplied using a quadrature encoder mounted to the part or the customer’s puller. 2-6 l Description SECTION 3 Installation Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . 3-2 C o n n e c t i n g t h e M a i n Po w e r S o u r c e . . . . . . . . . . . . 3 - 5 Installing the Encoder . . . . . . . . . . . . . . . . . . . . 3-6 Installing and Replacing the Cutter Blade . . . . . . . 3-7 P r e p a r i n g f o r Te s t i n g . . . . . . . . . . . . . . . . . . . . 3 - 1 0 Te s t i n g t h e I n s t a l l a t i o n . . . . . . . . . . . . . . . . . . . 3 - 1 0 Installation l 3-1 3 Po s i t i o n i n g t h e T G C G u i l l o t i n e . . . . . . . . . . . . . . . 3 - 4 Installation Preparing for Installation . . . . . . . . . . . . . . . . . . 3-3 Unpacking the Boxes The TGC Guillotine Cutter typically arrives in a single crate. CA U T I O N : L i f t i n g To avoid personal injury or damage to the cutter, lift the cutter using a forklift or hoist with straps that have been positioned at the cutter’s center of gravity. 105-555-104 Conair Y=0 M=0 TS Saw K=100 C=0 K=30 Y=0 C=10 M=5 Y=100 K=0 C=50 M=0 Bayfol UV-1 printed 10 mil carrier Second surface backing on white 3M 468 adhesive Black Grey Green 3-2 l Installation 1 Carefully uncrate the cutter and its components. 2 Remove all packing material, protective paper, tape, and plastic. Compare contents to the shipping papers to ensure that you have all the parts. 3 Carefully inspect all components to make sure no damage occurred during shipping. Check all wire terminal connections, bolts, and any other electrical connections, which may have come loose during shipping. 4 Record serial numbers and specifications in the blanks provided on the back of the User Guide's title page. This information will be helpful if you ever need service or parts. 5 You are now ready to begin installation. Preparing for Installation You need these tools for installation: ❒ ❒ ❒ ❒ ❒ ❒ ❒ wire strain relief 16- or 18-inch adjustable wrench set of Allen wrenches 1/2 inch open or box wrench #2 flat blade screwdriver multimeter flashlight Plan the location. Make sure the area where the guillotine cutter is installed has the following: • Clearance for safe operation and maintenance. Make sure there is enough clearance around the cutter for maintenance and servicing. WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r servicing may result in equipment damage or p e r s o n a l i n j u r y. This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. Installation l 3-3 3 Check the cutter’s serial tag for the correct amps, voltage, phase and cycles. All wiring should be completed by qualified personnel and should comply with your region’s electrical codes. Installation • A grounded power source. Po s i t i o n i n g t h e T G C G u i l l o t i n e C u t t e r 1 Move the cutter into position. Place the guillotine cutter in position downstream of the belt puller. CA U T I O N : L i f t i n g To avoid personal injury or damage to the cutter, lift the cutter using a forklift or hoist with straps that have been positioned at the cutter’s center of gravity. 2 Determine the best distance from the belt puller to the TGC Guillotine Cutter. For rigid products, leave enough space to allow the product to flex during the cutting cycle. In some cases, it may be necessary to allow 6-8 feet between the puller and cutter. 3-4 l Installation 3 Align the cutter with the extrusion line. 4 Measure the centerline height of the extrudate as it exits the extrusion die. Adjust all equipment on the extrusion line (sizing tank, cooling tanks, belt puller, and cutter) to this height. 5 Adjust the cutter’s floor lock/caster assembly to the center height of the extrusion line using a 16- or 18-inch adjustable wrench. Once the correct height is reached, adjust the pad assembly to remove the weight from the casters for operation. This minimizes machine vibration during the cutting cycle. 6 Use a plumb line or laser to check for a straight line from the extrusion die through each line component to the guillotine cutter center line of the table. Adjust as necessary. C o n n e c t i n g t h e M a i n Po w e r S o u r c e WA R N I N G : E l e c t r i c a l h a z a r d Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r s e r v icing may result in equipment damage or personal i n j u r y. All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. ON 1 Open the TGC Guillotine Cutter’s electrical enclosure. Turn the disconnect dial on 2 Insert the main power wire through the knockout in the side of the enclosure. Secure O OFF the door to the OFF or “O” position and open the door. the wire with a rubber compression fitting or strain relief. 3 Connect the power wires to the terminals indicated on the wiring diagram that came with your machine. 4 Check every terminal screw to make sure wires are secure. Gently tug each wire. If a wire is loose, use a screwdriver to tighten the terminal. 5 Connect the ground wire to the grounding point shown in the wiring diagram shipped with your unit. IMPORTANT: Always refer to the wiring diagrams that came with your cutter before making electrical connections. The diagrams show the minimum size main power cable required for your cutter, and the most accurate electrical component information. Installation l 3-5 3 Installation This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. Installing the Encoder CA U T I O N : H a n d l e w i t h c a r e . The encoder is a delicate piece of equipment and must be handled gently. Conair uses bi-directional encoders to ensure that only product that moves forward is counted. Installing the encoder consists of several parts: • The encoder • The measuring wheel • The connecting cable The encoder is fitted with a one foot circumference wheel which rides on Encoder either the upper belt of the belt puller or (for rigid profiles and pipe) on the extrudate itself upstream of the puller. Wheels Connecting Cable The encoder is supplied with an integral mounting bracket. How and where you attach the encoder to the puller depends on your particular puller and application. • If the wheel rides on the puller belt, make sure that its linear alignment is the same as the belt. Place the wheel near the center of the belt to minimize bouncing. Try to avoid cracks and other belt features that may affect accuracy. • Make sure the location allows you to keep the wheel clean. Any small buildup on the wheel will affect its circumference and change the cut length. After the encoder is installed, attach it to the TGC control using the supplied cable. The cable receptacle has been hard-wired to the control at the factory. 3-6 l Installation Installing and Replacing the Cutter Blade DA N G E R : S h a r p B l a d e a n d P i n c h H a z a r d ! Most injuries caused by sharp blades occur when the equipment has been turned off. Handle blades with care at all times. • Always wear cut-resistant gloves when the blade guard is open and when handling blades. • Always lock out power to the cutter before opening any guards. • Always wait until the cutter blade has completely stopped moving before opening the cutter guard (approximately five minutes). O OFF Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. Depending on how your TGC Guillotine cutter was shipped, you may ned to install the blade. This procedure explains how to access the blade area, remove a worn blade, and install a new blade. 1 Verify that the power to the machine is off, the electrical disconnect is in the OFF position, and the power supply is locked out according to established procedures. 2 Remove the cutter head side panel. You can remove either side. Access is available from either. The panel is held in place by four fasteners. (Continued) Installation l 3-7 3 WA R N I N G : E l e c t r i c a l h a z a r d ON Installation Guillotine Cutters are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury. Installing and Replacing the Cutter B l a d e (continued) DA N G E R : S h a r p B l a d e a n d P i n c h H a z a r d ! Most injuries caused by sharp blades occur when the equipment has been turned off. Handle blades with care at all times. • Always wear cut-resistant gloves when the blade guard is open and when handling blades. • Always lock out power to the cutter before opening any guards. • Always wait until the cutter blade has completely stopped moving before opening the cutter guard (approximately five minutes). Guillotine Cutters are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury. 3 ✐ Remove the brass blade guide. This blade guide is held in place with four fasteners. Note that the top fasteners and bottom fasteners may be a different length. Take note of which bolts go in which locations. Note: The brass blade guide sits snugly in the guillotine head. This tight fit ensures that the blade stays aligned. Removing the blade guide may require patience, gently rocking the guide back and forth or tapping gently with a small rubber mallet until it can be removed by pulling straight out from the cutter head. (Continued) 3-8 l Installation Installing and Replacing the Cutter B l a d e (continued) 5 Loosen the two blade setscrews. You will be able to see the blade move. Hold on to the side of the blade, making sure that the blade does not drop out of the blade mount. 6 Carefully slide the blade out of the holder. Use caution the blade will be sharp. 7 Replace the blade with a new or sharpened blade. Use caution - the blade will be sharp. 8 Reverse the disassembly procedure to reassemble the guillotine blade head. Installation l 3-9 3 Remove the two blade mount bolts. Installation 4 P r e p a r i n g f o r Te s t i n g 1 Make sure all components are installed according to assembly drawings. Make sure that all bolts on the TGC Guillotine have been tightened. 2 Check that cutter is firmly locked into position with the anchoring screws. 3 Check that all wiring conforms to electrical codes and all wiring covers are in place. 4 Connect the air supply. Te s t i n g t h e I n s t a l l a t i o n 1 Turn on the main disconnect. Plug in the main power cord and turn on the main disconnect. 2 Check that the E-Stop button is in the out, extended position. 3 Press the vacuum start button. Check the rotation of the vacuum motor for correct phasing. (The phase in your plant may be different from the Conair factory.) 4 Press the cutter start button. Turn off the cutter and vacuum. 5 Make a sample cut. Press the manual cut button. The guillotine cutter should make one sample cut. If the guillotine cutter is not working properly at any time, turn it off immediately and refer to the Troubleshooting section of this User Guide. If you do not encounter any problems, proceed to the Operation section. 3-10 l Installation SECTION 4 Operation TGC Guillotine Splash Screen. . . . . . . . . . . . . . . . 4-2 How to Navigate the Control Screens . . . . . . . . . . 4-3 TGC Guillotine Control Instructions Main Screen . . 4-5 TGC Guillotine Control Instructions Menu Screen. . . 4-6 The Cutter Control . . . . . . . . . . . . . . . . . . . . . . 4-36 M a c h i n e Fr a m e a n d S u p p o r t S y s t e m . . . . . . . . . . 4 - 3 7 Blade Height Adjustment . . . . . . . . . . . . . . . . . . 4-37 Upper Clamp Adjustment . . . . . . . . . . . . . . . . . . 4-38 Po w e r S u p p l y . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 8 C o n t r o l Pa n e l s . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 8 Pneumatic Cylinder Operation . . . . . . . . . . . . . . 4-39 Electrical Operation . . . . . . . . . . . . . . . . . . . . . 4-40 Machine Lubrication . . . . . . . . . . . . . . . . . . . . . 4-41 System Inspection . . . . . . . . . . . . . . . . . . . . . . 4-41 Blade Replacement . . . . . . . . . . . . . . . . . . . . . . 4-42 Chip Collection Shrouds & Blower Connection . . . . 4-43 Operation l 4-1 4 Control Function Descriptions . . . . . . . . . . . . . . 4-16 Operation Control Function Flow Charts . . . . . . . . . . . . . . . . 4-8 TGC Guillotine Cutter Splash Screen This initial startup screen appears for the first three seconds while the equipment initializes. 4-2 l Operation How to Navigate the Control Screens Navigate through the TGC Control Screens by touching any black text which opens a numeric keypad or pop up window. The colored text is not selectable and represents current data being displayed. (Continued) Operation l 4-3 4 Operation Example of Pop Up Number Pad How to Navigate the Control Screens (continued) Example of Pop Up Keypad 4-4 l Operation TGC Guillotine Cutter Operator Instructions Main Screen ✐ Note: The screen displayed here is for sample purposes. Depending on the operational mode selected, the screen will display either the Cycle time, Cut length 1, or Hold off delay setting. They are all shown simultaneously here for illustration purposes. Note: Depending on options ordered, modes selected, or customized settings, the screens on your TGC may not appear exactly as shown. These screens are meant to be a representation of standard screens. A manual cut button allows triggering a cut from the HMI. The cutter has a built in part counter. The part counter can be enable/disabled, and turned on/off. To access this, touch the count value in the display. Operation l 4-5 4 The TGC Guillotine has three (3) modes of operation. The currently selected mode is displayed directly above the running indicator. The cutter mode can only be changed when the cutter is stopped. To change the mode touch the current mode indicator. A pop-up window will appear allowing mode selection. The three (3) sources of demand cutting are: “Encoder”, “Timer” and “End Sense”. ✐ Operation The main page is displayed automatically upon power up after the system is done initializing. The main page is where most machine control functions are performed. From here the TGC Guillotine can be started and stopped. Touch the green start button to start the guillotine. Touch the red stop button to stop the guillotine. The running indicator directly above the start/stop buttons indicates current state of the cutter. This will display “Running” after touching the start button. After touching the stop button, this indicator will display “Stopping” while the guillotine is returning to the home position. After the guillotine has come to a complete stop it will display “Stopped”. TGC Guillotine Cutter Control: Menu bars Menu bar 1 Menu bar 2 The menu page is the root page for screen navigation. The row of buttons at the top of the menu page allow access to specific pages. Pressing the arrow button in the Menu bar will select Menu bar #1 or Menu bar #2 4-6 l Operation Main page: This will take you back to the main page. Units of Measure page: This page allows customer to set the units of measure to English or Metric. Recipes page: This page allows access to the recipe storage system. The current setup of the machine running parameters can be save to a recipe file. The system allows storage of 100 recipes. The running parameters can be changed by loading a saved recipe file. Security page: This page allows for changing the security settings for various functions of the TGC Guillotine. Proper login access is required to make changes to these settings. Arrow buttons: This forward button from Menu bar #1 and backward button from Menu bar #2 allow access or toggling between the two menu bars. The functions listed above are from Menu bar #1. The functions listed below are from Menu bar #2. Language: This page allows changing the language setting of the control. About: This button navigates to the information page, where you can located the contact information for Conair, the current program version, and the HMI build version. This page is also the location to start a Touch Calibration procedure for calibrating the touch functionality of the screen. TGC Guillotine Cutter Control: Menu Screen ✐ Note: Depending on options ordered, modes selected, or customized settings, the screens on your TGC may not appear exactly as shown. These screens are meant to be a representation of standard screens. Manual Functions page: This page gives the User access to all manual functions of the TGC Guillotine Cutter. Encoder Scaling page: This page allows access to the master encoder input scaling parameters. The TGC uses a quadrature encoder input signal to measure product length. These parameters scale encoder pulses to product length. Control Status page: This page allows access to the TGC control module status. The information displayed on this page would be used to help troubleshoot problems encountered with the guillotine. Drive Status page: This page allows access to the TGC drive module status. The information displayed on this page would be used to help troubleshoot problems encountered with the guillotine. Input Status page: This page allows access to the TGC control digital input status. The information displayed on this page would be used to help troubleshoot problems encountered with the guillotine. Output Status page: This page allows access to the TGC control digital output status. The information displayed on this page would be used to help troubleshoot problems encountered with the guillotine. Operation l 4-7 4 This page gives the User access to the clamp delay and cut delay for the TGC Guillotine Cutter. It also includes settings for the dump table, if equipped. Operation Timers page: Control Function Flow Charts 4-8 l Operation Control Function Flow Charts (continued) Operation l 4-9 4 Operation (Continued) Control Function Flow Charts 4-10 l Operation (continued) Control Function Flow Charts (continued) Operation l 4-11 4 Operation (Continued) Control Function Flow Charts 4-12 l Operation (continued) Control Function Flow Charts (continued) Operation l 4-13 4 Operation (Continued) Control Function Flow Chart 4-14 l Operation (continued) Control Function Flow Charts (continued) Operation l 4-15 4 Operation (Continued) Control Function Descriptions Main Page The main page is displayed automatically upon power up after the system is done initializing. The main page is where most machine control functions are performed. In this sample screen, all options are shown. In your control, different options will be shown based upon which Mode you are operating in. Date and Time Pop Up Window This page displays a pop up screen with the current date and time. Touching the date and time allows the User to correct for the current date and time. 4-16 l Operation Control Function Descriptions (continued) Mode Selection from Main This page allows you to select the mode for cutting. Modes can only be changed when the cutter is off. (Continued) Operation l 4-17 4 Operation Cut Enable Turned Off Note on the above screen that the “Cut enable” knob selection is pointing to “off”. Touching the knob will rotate the selection to “On.” Control Function Descriptions (continued) Cut Enable Turned On Note on the above screen that the “Cut enable” knob selection is pointing to “On”. Touching the knob will rotate the selection to “Off.” Main In Encoder Mode Note on the above screen that the Mode is set to “Encoder”. Touching the text “Mode:” allows you to change the mode of operation for the guillotine. Available modes of operation are: Encoder, End sense, and Timer. 4-18 l Operation Control Function Descriptions (continued) Part Counter Total From the main screen, if you touch the part counter count, this window wil pop up. From this window, you can turn part counting on or off and can reset the total count. (Continued) Operation l 4-19 4 Operation Cut Length in Encoder Mode From the main screen, if you press the text “Cut length:” the above pop up window opens. Here you can enter the desired cut length then press the enter key. The numeric key pad will disappear after the enter key is pressed as long as the value is in the acceptable range. Control Function Descriptions (continued) Hold off delay From the main screen, in End sense mode, you can enter the amount of time you would like the photo eye or switching signals to be ignored after the cut is made. Note: you do not want to set the value too long, or you may start missing the next cut. Main In End Sense Mode This page uses a proximity switch, mechanical switch, or some type of sensing device that triggers the cut. The sensing device must be placed at a distance from the downstream side of the blade. Pressing on the “Mode” text will enable you to change the mode of operation between End sense, Timer, and Encoder. 4-20 l Operation Control Function Descriptions (continued) Cycle Time Pop Up in Timer Mode When in Timer mode, pressing the cycle time text will display this pop up window. From here, you can adjust the cycle time. (Continued) Operation l 4-21 4 Operation Main In Timer Mode. In Timer mode, the guillotine uses a cycle time to determine the cut frequency. Pressing on the “Mode” text will enable you to change the mode of operation between End sense, Timer, and Encoder. Control Function Descriptions (continued) Timers From Main Screen On the main screen in Timer mode, touching the “Timers” button will display the Timers Screen. From this screen, you can adjust the clamp delay, the cut delay, the dump table delay, and the dump table duration. 4-22 l Operation Control Function Descriptions (continued) (Continued) Operation l 4-23 4 Operation Timer Start Delay Pop Up On the main screen in Timer mode, touching the “Timers” button will display the Timers Screen. Pressing Start delay on this screen displays the above window to set the delay. Control Function Descriptions (continued) Menu Page The menu page is the root page for screen navigation. Units of Measure Page Selecting “inches” sets length units to inches and speed units to feet/min, (FPM). Selecting “centimeters” sets length units to centimeters and speed units to meter/min, (MPM). 4-24 l Operation Control Function Descriptions (continued) Recipes Three recipe function can be performed. They are “Load from selected”, “Delete selected” and “Save to selected”. To perform one of these functions a recipe file must first be selected. To select a recipe from the recipe file, touch the name of the desired recipe from the list of five currently displayed. The recipe name and number will appear as the selected recipe file. The name of the selected recipe can be changed by touching the selected recipe name. (Continued) Operation l 4-25 4 Operation Recipes Page Recipes Page The recipe page allows access to the recipe storage/retrieval system. Up to 100 recipe files are available and are number 1 thru 100. Each recipe file can be given a name up to 40 characters. Five recipe file numbers/names are displayed at once. To view other recipe file names touch the “Pg Up” or “Pg Dn” buttons. The recipe files are scrolled five at a time. Control Function Descriptions (continued) Recipe Name Edit Page When you touch on the name of a recipe from the Recipes page, you are able to edit the name of that recipe. From here, use the keypad to name the recipe, and press Enter when complete to return to the Recipes screen. Recipe Save Page The “Save to selected” function is available anytime. This function will save the active parameters to the selected recipe file. 4-26 l Operation Control Function Descriptions (continued) Recipe Load Page The “Load from selected” function is only available when the cutter is stopped. This function will load the parameters from the recipe file into the active parameters. (Continued) Operation l 4-27 4 Operation Recipe Delete Page The “Delete selected” function is available anytime. This function will set the name of the selected recipe file to “Empty”. The actual parameter values in the recipe file are not deleted Control Function Descriptions (continued) Manual Functions. This screen allows you to test cylinders and solenoids that operate guillotine functions for cleaning and troubleshooting. Control Status This page allows access to the TGC Guillotine control module status. The information displayed on this page would be used to help troubleshoot problems encountered with the guillotine operation. 4-28 l Operation Control Function Descriptions (continued) Input Status This page allows access to the TGC Guillotine control digital input status. The information displayed on this page would be used to help troubleshoot problems encountered with switches/photo eyes, eliminating the need to meter connections in the control box. (Continued) Operation l 4-29 4 Operation Drive Status This page allows access to the TGC Guillotine module status. The information displayed on this page would be used to help troubleshoot problems encountered with the guillotine operation. Control Function Descriptions (continued) Output Status This page allows access to the cutter servo control digital output status. The information displayed on this page would be used to help troubleshoot problems encountered. Encoder Scaling This screen is used for setting the encoder for your application depending on where you have mounted the encoder and what encoder you are using. 4-30 l Operation Control Function Descriptions (continued) Encoder Scale Factor Pop Up This screen allows further adjustment of the encoder for your application. (Continued) Operation l 4-31 4 Operation Encoder Counts Pop Up If you touch the “Encoder counts” text on the Encoder screen, this is the pop-up window to set the number of encoder pulses per revolution for the encoder used. The machine is set at the factory and this setting should not need changed. Control Function Descriptions (continued) Touch Calibrate Page The HMI touchscreen can be calibrated by this page. Selecting this page begins the calibration procedure. The user is guided to touch various points on the screen to complete the procedure. Touch Calibrate Success Page This message displays when you have successfully calibrated the touch screen. 4-32 l Operation Control Function Descriptions (continued) (Continued) Operation l 4-33 4 Operation Touch Calibrate Failure Page This message displays if the calibration has failed. This is usually because too much time has passed between touches, or there is a problem with the touch functionality of the screen. Control Function Descriptions (continued) Security This window will pop up anytime you are trying to access an area or change a setting that requires a higher security level. From here, you can enter your username and press the enter key. Security Username From here, you can enter your username and press the enter key. 4-34 l Operation Control Function Descriptions (continued) (Continued) Operation l 4-35 4 Operation Security Password From here, you can enter your password and press the enter key to access the area you were trying to access. The Cutter Control IMPORTANT: Always refer to the wiring diagrams that came with your guillotine before making electrical connections. The diagrams show the minimum size main power cable required for your cutter, and the most accurate electrical component information. I M P O RTA N T: Before applying power, ensure that the GUILLOTINE BLADE and TABLE FORWARD valves are closed (fully clockwise). 1 Connect the electrical line cord to a source of power. compatible with the nameplate on the TGC Guillotine. 2 Connect the air supply to the FRL (filter-regulator-lubricator) on the cutter. 3 Turn the main disconnect switch to the ON position. 4 Press Start or (if equipped with Dust Collector) turn Dust Collector power “ON” first and then press “START”. 5 Check the guillotine function. Make sure that the FRL is set for 65 PSI. 6 Press Manual Cut. 7 Adjust the Table Forward speed control to match the approximate line speed (if a pneumatic control is used). 8 Adjust the Table Return speed control to the suitable travel return speed (if a pneumatic control unit is used). 9 Adjust the clamp pressure regulator to grasp the profile firmly. ✐ 4-36 l Operation Note: The TABLE RETURN pressure must be set high enough to return the table to the start position and trigger the TABLE START micro-switch from the front or operator side of the unit. Machine Frame and Support System The machine frame is constructed of welded steel that has been primed and painted to resist corrosion and provide a maintenance free finish. The frame is supported by, four leveling screws, that both permanently fix the position of the unit and also help accommodate any uneven flooring. These screws have a welded hex nut to allow adjustment with a wrench. The motors and machine components are mounted inside the frame and completely guarded for operator safety. These and all guards should always remain securely in place when machine is running and should be re-installed after any maintenance procedures that have required their removal. 4 Operation Operation l 4-37 Clamp Adjustment On the TGC Guillotine, the clamp cylinders will extend until contact is made with the part. The only necessary adjustments are flow controls which adjust the speed of the clamp extension and retraction, and pressure regulation to adjust the clamp force. To adjust the speed of the clamp extending and retracting: 1 Adjust the flow controls for the guillotine head, which will adjust the speed of the clamp. 2 Continue adjusting as necessary to achieve the desired result. To adjust the clamp force or pressure: 1 Adjust the pressure regulation, which will adjust the force of the clamp on the product. 2 Continue adjusting as necessary to achieve the desired result. Po w e r S u p p l y This equipment is powered by either 230 or 460 VAC , Three Phase, as specified on the machine nameplate. 1 Connect the machine power through a fused disconnect of proper rating. Make sure the power is grounded through the power cable to the plant electrical ground. C o n t r o l Pa n e l s The operator control panels are located on the front of the cutter frame. The pneumatic control panel is located near the operator controls platform. It consists of a pressure regulator, pressure gauge, and flow controls. All items are labeled, and easily accessible. 4-38 l Operation Pneumatic Cylinder Operation The traveling table, guillotine blade, and clamp assemblies are moved with air cylinders. The speed of the movement of the carriage assembly is controlled by flow controls located on the operator panel. Clockwise rotation will slow the table speed and counterclockwise rotation will increase the table speed. The guillotine blade is moved up and down with an air cylinder located on the table. It is controlled by the HMI. . The clamp assembly is moved up and down by air cylinders mounted above the clamp. They are controlled by flow controls mounted on the Cylinders. Clockwise rotation will slow the clamp movement speed and counterclockwise rotation will increase the clamp movement speed. The table and clamp pressure setting is adjusted with a pressure regulator located on the operator panel. The pressure level setting is displayed on the gauge located above the regulator. The table and clamp pressure should never exceed 60 PSI. Use the “Manual Jog” page to make these adjustments. IMPORTANT: This unit should always be supplied with clean dry air. Incoming pressure should be set at approximately 65 PSI. Maximum pressure is 70 PSI. Operation l 4-39 4 This unit should always be supplied with clean dry air. Incoming pressure should be set at approximately 65 PSI. Maximum pressure is 70 PSI. Operation The main filter/regulator/lubricator is mounted on the side of the machine near the electrical enclosure and should be maintained as described in the manufacturers documentation. Electrical Operation The operation of the guillotine consists of an automatic sequence of events. See Section 1: Introduction, How to use the Lockout Device. 1 To start the TGC Cutter, the main power must be on and the appropriate air supply must be given to the machine. With the power on, the control panel will have the power light illuminated. 2 To start the cutter, push the start button. Once the cutter is started, push the yellow manual cut button and the machine will start its automatic cycle. The clamps will come down and the table will begin to travel away from its home position. Immediately after this happens, the guillotine assembly will move the blade until it reaches its up limit switch. Upon reaching this switch, the blade will return to the home position, the clamps will raise and the table will return to its home position, completing one cycle. IMPORTANT: An important reminder is that the speed settings of the pneumatic flow controls will affect the cycle time of the machine. The flow controls must be set properly to a compromise between cycle time and cut quality. Flow control settings should be adjusted at this time and fine-tuned during the initial phase of the guillotine operation. 4-40 l Operation Machine Lubrication The machine is supplied to you completely lubricated. After running the unit for long periods of time, this lubrication will break down and become useless. Follow this lubrication chart for optimum performance. Component Type of Lubricant Duration Table Roller Bearings Chassis Lube 2-6 months System Inspection Although this unit was designed to require a minimum amount of maintenance, it should be inspected periodically to insure that it remains in top operating condition. Items to inspect are as follows: Guillotine blade - The cutter blade, will after time, begin to wear. The blade should be visually inspected for wear and replaced as necessary. Operation l 4-41 4 Operation Pneumatic System - Approximately once every 12 months or sooner if able, all system pneumatic components should be visually inspected. All hoses should be checked for wear or damage. All regulators and flow controls should be adjusted through their usable ranges to insure proper operation. Blade Replacement 1 Lock out and tag out the power to the TGC Guillotine Cutter. See Section 1: Introduction, How to use the Lockout Device. 2 Wait for the blade and cylinder to stop moving completely. 3 Refer to “Installing or Changing the Cutter Blade” in the Installation section of this User Guide. WA R N I N G : E l e c t r i c a l h a z a r d Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. CA U T I O N : M o v i n g p a r t s Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed and all safety guards are reinstalled. 4-42 l Operation SECTION 5 Maintenance M a i n t e n a n c e Fe a t u r e s . . . . . . . . . . . . . . . . . . . . 5 - 2 Wa r n i n g s a n d C a u t i o n s . . . . . . . . . . . . . . . . . . . . 5 - 2 Maintenance Overview . . . . . . . . . . . . . . . . . . . . 5-3 Preventative Maintenance Schedule . . . . . . . . . . . 5-4 Checking Electrical Connections . . . . . . . . . . . . . 5-6 5 Maintenance Maintenance l 5-1 M a i n t e n a n c e Fe a t u r e s The TGC Guillotine cutter needs regular, scheduled maintenance for peak performance. Among the features that require maintenance are: • • • • • • • • • Blades Blade mounting hardware Product guides The guard hardware Blade alignment Floor locks Carriage slide system Electrical cables Control panel lights Wa r n i n g s a n d C a u t i o n s To maintain the best performance of the cutter it must be cleaned and inspected regularly. Maintenance includes a daily, weekly, quarterly, and semi-annual (every 6 months) schedule. Use this maintenance schedule as a guide. You may need to shorten the time of the maintenance schedule, depending on how often you use the guillotine cutter, and the types of material flowing through it. Follow all precautions and warnings when working on the equipment. WA R N I N G : I m p r o p e r I n s t a l l a t i o n , o p e r a t i o n , o r s e r v i c ing may result in equipment damage or personal i n j u r y. This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. 5-2 l Maintenance (Continued) Wa r n i n g s a n d C a u t i o n s (continued) WA R N I N G : Vo l t a g e h a z a r d This equipment is powered by alternating current, as specified on the machine serial tag and data plate. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in severe personal injury and erratic machine operation. Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. DA N G E R : S h a r p B l a d e s ! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times. • TGC Guillotines are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury. Maintenance Overview This section describes the daily, weekly, monthly and semi-annual maintenance schedules that should be performed when changing materials or lines, or when changing equipment, as well as the maintenance procedures to follow. Cutting either flexible or rigid materials generates tremendous shock and vibration to the entire unit. Anything that can loosen, will over time. To maintain the best performance, follow this maintenance schedule and develop an effective preventative maintenance program. Maintenance l 5-3 5 Maintenance • • Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. Always lock out power to the guillotine before opening any guards. Always wait until the cutter head has completely stopped before opening the knife guard. Always wait until the blade has completely stopped before opening the guillotine guards (approximately 2 minutes.). Preventative Maintenance Schedule • Daily ❒ Checking guillotine blade(s) Clean, sharpen or replace as needed (see Section 4, Blade Replacement). ❒ Inspecting the blade mounting hardware. The blade securing nuts should regularly be tightened. ❒ Inspecting the cutter product guides for wear and alignment. ❒ Inspecting cutter alignment. Proper cutter alignment is critical for optimum performance. Use a plumb line or laser to check for a straight line from the extrusion die to the guillotine guides. ❒ Check floor locks. It is always recommended that the weight be removed from the casters for optimum stability during cutting cycles. Check to see if the floor locking mechanism is properly adjusted. • Weekly ❒ Blow or vacuum, dust and chips from all surfaces of the TGC. Open pneumatic and electrical enclosures and remove the dust and chips from all components. ❒ Check that the FRL (filter-regulator-lubricator) for the air input is filled with oil and that the oilier is working. Pressure should be set for around 60 PSI. This unit also has an automatic drain for any moisture that may develop. The bowl should be kept clean to ensure it will operate properly. 5-4 l Maintenance (Continued) Preventative Maintenance Schedule (continued) • Quarterly ❒ Blow or vacuum, dust and chips from the inside the cutter. Remove all dust and chips from inside all control cabinets. Remove any excess oil from the pneumatic enclosure. ❒ Verify that all electrical terminals are tight. ❒ Check that all air lines are in order (free of cuts or abrasions). ❒ Check that the adjustable flow controls on the BLADE UP cylinder is set for a smooth downward return. ❒ Check that the adjustable flow controls on the clamp cylinder are set so that the clamp operates quickly a slow cycle on the clamp-down will cause inaccurate cuts in length. ❒ Check the condition of the clamp pads. If worn or damaged, replace with a new set of pads. ❒ Check the condition of the clamp pads. If worn or damaged, replace with a new set of pads. ❒ Check the condition of the blade. If the blade is dull, have the blade replaced. WA R N I N G : E l e c t r i c a l h a z a r d Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed and all safety guards are reinstalled. Maintenance l 5-5 5 CA U T I O N : M o v i n g p a r t s Maintenance Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. Checking Electrical Connections WA R N I N G : E l e c t r i c a l H a z a r d Before performing any work on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. WA R N I N G : I m p r o p e r I n s t a l l a t i o n , o p e r a t i o n , o r s e r v i c ing may result in equipment damage or personal i n j u r y. This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. 1 Be sure the main power is disconnected and the TGC is locked out. Always disconnect and lock out the main power source before opening the unit or servicing. 2 Turn the main power disconnect to the off position before opening the electrical enclosure on the back of the guillotine, or the back of the control. This is a safety device to prevent you from opening the doors if the power is still on. Main power safety disconnect 5-6 l Maintenance (Continued) Checking Electrical Connections (continued) 3 Open the electrical enclosure. 4 Inspect all wires and connections. Look for loose wires, burned contacts, and signs of over-heated wires. Have a qualified electrician make any necessary repairs or replacements. 5 Close the electrical enclosure door. 6 Inspect the exterior power cords. Cords should not be crimped, exposed, or rubbing against the frame. If the main power cord runs along the floor, make sure it is not positioned where it could rest in pooling water or could be run over and cut by wheels or casters. 5 Maintenance Maintenance l 5-7 5-8 l Maintenance SECTION 6 Tr o u b l e s h o o t i n g Before Beginning . . . . . . . . . . . . . . . . . . . . . . . 6-2 A Fe w Wo r d s o f C a u t i o n . . . . . . . . . . . . . . . . . . . 6 - 2 Identifying the Cause of a Problem . . . . . . . . . . . 6-4 Electrical Problems . . . . . . . . . . . . . . . . . . . . . . 6-5 Product Quality Problems . . . . . . . . . . . . . . . . . . 6-6 T G C G u i l l o t i n e Fa u l t M e s s a g e s . . . . . . . . . . . . . . 6 - 8 Checking the Servo Amplifiers . . . . . . . . . . . . . . . 6-9 Checking the Encoder . . . . . . . . . . . . . . . . . . . . 6-9 6 Tr o u b l e s h o o t i n g Tr o u b l e s h o o t i n g l 6 - 1 Before Beginning You can avoid most problems by following the recommended installation, operation and maintenance procedures outlined in this User Guide. If you have a problem, this section will help you determine the cause and tell you how to fix it. Before you begin troubleshooting: ❏ Find any wiring, parts, and assembly diagrams that were shipped with your equipment. These are the best reference for correcting a problem. The diagrams will note any custom features or options not covered in this User Guide. ❏ Verify that you have all instructional materials related to the cutter. Additional details about troubleshooting and repairing specific components are found in these materials. ❏ Check that you have a manual for other equipment connected in the system. Troubleshooting may require investigating other equipment attached to, or connected with the cutter. A Fe w Wo r d s o f C a u t i o n WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n o r s e r v i c i n g m a y r e s u l t i n e q u i p m e n t d a m a g e o r p e r s o n a l i n j u r y. This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. All wiring, disconnects, and fuses should be installed and adjusted by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. WA R N I N G : E l e c t r i c a l h a z a r d . Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. 6 - 2 l Tr o u b l e s h o o t i n g A Fe w Wo r d s o f C a u t i o n (continued) DA N G E R : S h a r p B l a d e s ! Most injuries caused by knife blades occur when the cutter has been turned off. Handle blades with care at all times. • • • Always wear cut-resistant gloves when the cutting chamber is open and when handling blades. Always lock out power to the cutter before opening the cutting chamber. Always wait until the guillotine has completely stopped before opening the cabinet door. TGC Guillotine Cutters are equipped with several safety devices to ensure safe operation. Never remove or disable these devices to sustain production. Operating without these devices can cause severe injury. 6 Tr o u b l e s h o o t i n g Tr o u b l e s h o o t i n g l 6 - 3 Identifying the Cause of a Problem The Troubleshooting section covers problems directly related to the operation and maintenance of the TGC Guillotine Cutter. This section does not provide solutions to problems that originate with other equipment. Additional troubleshooting help can be found in manuals supplied with the other equipment. The main problems you could encounter with the TGC are: • Cutter operation problems, which focus on problems that are clearly related to the operation of the cutter’s electrical control systems. • Plastic product quality concerns, which deal with product characteristics that may be related to cutter operation. Of course, other sections of the extrusion line also influence the quality of the extruded product. This section does not provide solutions to problems originating with other equipment on the extrusion line. Additional troubleshooting help can be found in the documentation manuals included with this User Guide. 6 - 4 l Tr o u b l e s h o o t i n g Electrical Problems Look in this section when you have problems such as lights on the control that are working improperly, buttons that do not execute the function properly, and when information input is not executed properly. Symptom Possible Cause Solution TGC will not start. The E-stop button is depressed. Make sure the E-stop is extended. Disconnect in the off position. Turn disconnect to the on position. 6 Tr o u b l e s h o o t i n g Tr o u b l e s h o o t i n g l 6 - 5 Product Quality Problems Symptom Possible Cause Solution Cut not square. Product guides not aligned square to the blade face. Re-align the product guides. Ensure that the rear guide is square with the blade and tighten. Adjust the front guide accordingly allowing enough clearance for smooth product passage. Crack or fractures in cut surfaces. Blade up speed too fast. Adjust speed control for blade feed into part (slower). Incorrect blade design. Investigate blade choice for the application. Incorrect cooling of extrudate. Improve the molecular structure with variation of cooling time or temperature. General poor cut quality. Incorrect blade design. Investigate blade choice for the application. Product melting at cut. Dull Blade. Have blade sharpened or replaced. Blade up speed too slow. Adjust speed control for blade feed into part (faster). Incorrect blade design. Investigate blade choice for the application. 6 - 6 l Tr o u b l e s h o o t i n g Product Quality Problems (continued) Possible Cause Solution Incorrect cut length. Encoder or input device problem. Check encoder or input device. Puller problem. Check puller for drive consistencies or any belt to product slippage. Counter problem. Check cut length counter. Cutter clamps not holding. Adjust clamp pressure. Inspect clamp tooling for wear or damage. Roller ways dirty. Clean roller ways. Rodless cylinder problem. Check and clean rodless cylinder. Solenoid problem . Check table actuation solenoid for proper operation. Low air pressure. Check main system regulator for incoming air pressure settings. Table motion inconsistent. 6 Tr o u b l e s h o o t i n g Symptom Tr o u b l e s h o o t i n g l 6 - 7 T G C G u i l l o t i n e Fa u l t M e s s a g e s Symptom Possible Cause Solution Release the emergency stop buttons and close the guard doors. Press the emergency stop reset pushbutton. 0. No message. 1. The emergency stop circuit has been activated. Plc input 1 must be on. 2. A table overtravel was detected. 6 - 8 l Tr o u b l e s h o o t i n g Table position was not correct for cutting process. Adjust settings to complete the cut sooner. Checking the Servo Amplifier The servo amplifier is equipped with a digital readout that can be seen through the viewing window on the electrical enclosure. This display shows amplifier status and error messages. Refer to the supplier's documentation included with this User Guide. ✐ NOTE: Make sure you look for servo amplifier messages before you shut off the power. Checking the Encoder When the encoder is working properly, the measurement displayed will count up to the preset and reset to zero. 1 Check all connections. 2 Check the encoder cable for damage. If necessary, replace. 3 Check the connector that attaches the cable to the encoder. Internal wiring may be shorted out if this connector is not handled properly. 4 Check the encoder itself. There should be no play in the shaft. WA R N I N G : D e l i c a t e e q u i p m e n t The encoder is a delicate piece of equipment. Any rough handling can damage fragile parts. 5 If all else fails, contact Conair Customer Service. See Appendix A. Tr o u b l e s h o o t i n g l 6 - 9 6 - 1 0 l Tr o u b l e s h o o t i n g We ’ r e H e r e t o H e l p Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use. How to Contact Customer Service To contact Customer Service personnel, call: ✐ Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee. Most manuals can be downloaded free of charge from the product section of the Conair website. www.conairgroup.com NOTE: Normal operating hours are 8:00 am - 5:00 pm EST. After hours emergency service is available at the same phone number. From outside the United States, call: 814-437-6861 You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department. Standard rates include an on-site hourly rate, with a one-day minimum plus expenses. B e f o r e Yo u C a l l . . . If you do have a problem, please complete the following checklist before calling Conair: ❒ Make sure you have all model, control type from the serial tag, and parts list numbers for your particular equipment. Service personnel will need this information to assist you. ❒ Make sure power is supplied to the equipment. ❒ Make sure that all connectors and wires within and between control systems and related components have been installed correctly. ❒ Check the troubleshooting guide of this manual for a solution. ❒ Thoroughly examine the instruction manual(s) for associated equipment, especially controls. Each manual may have its own troubleshooting guide to help you. ❒ Check that the equipment has been operated as described in this manual. ❒ Check accompanying schematic drawings for information on special considerations. Appendix l A-1 Equipment Guarantee Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The customer assumes the cost of transportation of the part or parts to and from the factory. Pe r f o r m a n c e Wa r r a n t y Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and maintained in the recommended manner as outlined in our quotation or specifications. Should performance not meet warranted levels, Conair at its discretion will exercise one of the following options: • Inspect the equipment and perform alterations or adjustments to satisfy performance claims. (Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication, improper installation, poor maintenance practices or improper operation.) • Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer. • Refund the invoiced cost to the customer. Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number (RGA) will be issued by Conair’s Service Department. Returned equipment must be well crated and in proper operating condition, including all parts. Returns must be prepaid. Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made. Wa r r a n t y L i m i t a t i o n s Except for the Equipment Guarantee and Performance Warranty stated above, Conair disclaims all other warranties with respect to the equipment, express or implied, arising by operation of law, course of dealing, usage of trade or otherwise, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. A-2 l Appendix